Reinforced articles



y 1966 A. N SPANEL 3,253,598

REINFORCED ARTICLES Filed Sept. 18, 1963 IN VEN TOR. L

F/ G. 3 ATTORNEY United States Patent 3,253,598 REENFORCED ARTICLES Abraham N. Spanel, Princeton, N.J., assignor to International Latex Corporation, Dover, Del., a corporation of Delaware Filed Sept. 18, 1963, Ser. No. 309,833 14 Claims. (Cl. 128521) This invention represents cooler and more comfortable articles such as girdles made of rubbery materials with liners of unique characteristics. More particularly the invention embraces rubbery goods provided with reinforcing, composite liners. In addition the invention embraces dipped, sprayed, latex or molded, sectionally cemented or stitched rubber fabric goods provided with liners of the aforesaid type with or without a layer of flock secured thereto.

It is known in the art that garments made of unsupported, perforated latex, rubber or other elastomer films, especially such articles as girdles, brassieres, and the like, are subject to accidental tearing, and this happens for the most part where the fingers of the wearer exert undue strain on -the perforations themselves. This finger damage even though the incidents may not be overwhelming in number, are costly, hazardous and embarrassing to the consumer, the store and manufacturer.

An important object of the instant invention is to provide corrective, practical and economical supporting means to the film.

An important objective of my invention is that it facilitates making a control garment such as a dipped or sprayed latex girdle, for example, with a substantially thinner wall in the substrate or carcass of the girdle, in order to give the wearer greater comfort without sacrificing the garments durability.

An equally important object is to make a product that is comfortable to the wearer by virtue of the controllable ventilation and evaporating features of the product.

Still another feature is to be found in the economy of cost in producing such an improved product.

A still further object is to provide dipped, sprayed, latex or molded, sectionally cemented or stitched rubber fabric goods with reinforcing liners and a layer of flock secured to the inner face of the goods.

According to the present invention articles with an inner surface adapted to contact the human body such as girdles, brassieres and the like are essentially characterized by the fact that they are provided with a composite, laminated liner which comprises a stretchable foamed layer with its 'back or reverse side contiguous with a reinforcing, stretchable or extensible fabric. In view of the fact that the fabric component of the liner is relatively extensible, the girdle or like article is supported and reinforced, particularly against finger damage, and a highly serviceable girdle may be made with an outer wall and foam liner each relatively thinner than would be the case if the girdle were made without the fabric component. The foam liner, the fabric component, and the outer wall or carcass of the girdle may each be perforated or not, or made porously preformed or not. When perforated, the holes or openings may "be of diflferent sizes and randomly or predeterminedly spaced. It is preferred that all three contain perforations or substantial porosity some of the holes in the composite liner being larger than some of the holes in the carcass, or vice versa, and some of the holes in the carcass communicating with the holes in the composite liner and other holes passing through both the carcass and the composite liner.

3,253,598 Patented May 31, 1966 The liner may be foamed fabric sheeting such as foamed elastomeric polyurethane, foamed Buna N, foamed polychloroprene and similar materials which are resistant to abrasion, ozone, body-oils and other body secretions. Elastomeric polyurethanes are especially advantageous in being capable of being made in relatively thin sheets of the order of A to in thickness while still retaining excellent resistance to abrasion, etc. Such liners slip on and off the body of the wearer easily especially if provided with a flocked surface of cotton, linen, rayon, silk or any of the other smooth man-made fibers, or in any desired combination of these.

Polyurethanes are presently preferred for making the foamed liners and are described as materials made from various base polymers reacted with diisocyanates to form polyurethane polymers, that is, polymers containing more than one urethane linkage 0 I II N C .O in the structure. The base polymers may vary widely as to chemical composition and molecular structure and may have a wide range of physical properties dependent.

upon the chemical composition. One method of preparing polyurethane compounds is to react an essentially linear polyester having terminal hydroxy groups with a diis'ocyanate. Polyethers are another class of materials which may be used to react with diisocyanates to form polyurethanes. When water is present, the reaction will produce carbon dioxide gas as a by-product which causes the mass of reaction product to become foamed.

The polyurethane polymers may be suitably produced from linear polyesters prepared by reacting polyhydric alcohols, for example ethylene and propylene glycols or mixtures thereof with polycarboxylic acids, for example, aliphatic dicarboxylic acids such as adipic, pimelic, sebacic, methyl adipic and succinic acids using an excess of the alcohol over the acid so that the resulting linear polyester contains terminal hydroxy groups. The polyester is then reacted with a diisocyanate, for example, an aromatic diisocyanate such as 1,4-toluene diisocyanate; naphthalene 1,5-diisocyanate and the like; also aliphatic diisocyanates such as hexamethylene diisocyanate. proper proportioning of the hydroxyl containing polymer and the diisocyanate, as is well known in the art, and carrying out the reaction in the presence of water, elastomeric foamed polyurethanes are produced. Polyalkylene ether glycols, usually referred to as polyethers, include polyethylene glycols, polypropylene glycols, polybutylene glycols and the like and are similarly suited for making elastomeric polyurethanes.

There are many kinds of polyesters, polyethers and diisocyanates which may be used to form polyurethanes and a fuller discussion may be found in the literature including US. Patents, 2,284,896; 2,292,443; 2,333,639; 2,374,163; 2,764,565; German Plastics Practice, by De Bell et al., 1946; and Polyurethanes, by B. A. Dombrow, Reinhold Publishing Co., 1957, etc.

In certain applications it is advantageous to provide the inner surface of the girdle or the like with a layer of relatively short, individual fibers of natural or man-made filaments such as cotton, linen, rayon, nylon, etc., otherwise known as flock.

The numerous modifications to which the invention is directed can better be described and understood by reference to the following drawings in which:

FIGURE 1 is a front view of a girdle with a cut-away portion showing the perforated liner.

FIGURE 2 is a rear view of the girdle of FIGURE 1.

preferably porous in character.

FIGURE 3 is a fragmentary view along lines 33 of I FIGURE 1 showing the relationship of the openings in the composite liner with those in the backing sheet or carcass of the girdle.

FIGURE 4 is a view of a backing sheet of rubber with a superposed, perforated composite liner united together or made contiguous with an adhesiveQor by producing a foamed surface on the reinforcing fabric which latter is Unlike in FIGS. 1 and 2, the perforations shown here are of relatively large size, the smaller or random sized ones not being shown.

FIGURE 5 is a view along lines 55 showing the relationship of the backing sheet and the-perforated composite liner.

FIGURE 6 is a cross sectional view of the article of FIGURE 5 after the backing sheet and composite liner have been perforated; also illustrating how the foamed liner and backing sheet of rubber, only, may be perforated.

FIGURE 7 is a cross-sectional piew of a girdle where flock is present on the reinforcing fabric.

One embodiment of the present invention is represented in FIGURES 1 through 3 which show a latex girdle 20 with an inner liner 21 of perforated, foamed polyurethane. In making the girdle, a girdle form is sprayed with liquid latex or is dipped into a bath of liquid latex to build up the desired thickness layer of latex according to principles well known in the art. The built-up layer of latex at this stage may be referred to as the latex substrate.

A thin polyurethane foam'sheet about 5 to 7 thick having interconnected cells is perforated, for example, with a A" punch with A spacings between the holes 22. It is to be understood that the holes may be larger or smaller and may be distributed in either a predetermined or random manner. The relatively thin polyurethane foam sheet is combined on one of its faces with a reinforcing stretchable fabric 40, preferably porous, and this flat laminate is then butt-cemented to produce a hollow composite liner in the form of a sheath or tube, which may be cylindrical or tapered, the reinforcing fabric being the inner surface of the sheath. The sheath preferably approximates the shape of the latex substrate.

The latex substrate is dipped into a bath of adhesive which may be a polyurethane adhesive or any suitable adhesive. Upon withdrawing from the adhesive bath,

layer 42 leaving the porous fabric 41 intact. The holes in the carcass may also be made relatively larger than the holes in the composite liner as illustrated by hole 240 in FIGURE 6. It is clear that there are many ways of making separate predetermined openings in a relatively thin sheet of composite foamed material, just as there are many ways of making predetermined openings in the carcass of the girdle. In one form it is preferred to perforate the composite liner by cutting with a die, generally referred to as clicking, and the carcass in the same manner, but it is to be understood that all possible methods are contemplated as being useful.

It is obvious that the composite liner may be formed in any desired manner. For example, the foam sheet may be united with the fabric by cementing the two together, cutting on the flat, and then cementing onto the inner surface of the girdle to form a laminate where the fabric layer is sandwiched between the outer 'girdle wall and the inner foam liner. Another method is to apply the reinforcing extensible fabric to the inner surface of the girdle carcass while it is still relatively wet with cement and thereafter apply to the fabric, with some pressure, the foam sheet, preferably with perforated or formed openings therein, resulting in a composite reinforcing liner with its foam surface to be worn next to the skin of the wearer.

The reinforcing extensible fabric can be made cheaply of porous cotton, linen, ramie or of elastomeric fabrics, or of man-made fiber-fabrics, preferably thin, sheet-like and/ or loosely woven in character.

The adhesive 35 which may be used to adhere the liner 21 to the backing sheet or carcass 26 of the girdle may be selected according to the nature of the carcass and the liner. The adhesive may be polyurethane adhesive, as previously stated, or may be any latex or elastomeric cement or rubber cement. The liner may, however, be secured to the carcass by other means.

With the composite foamed liner it is practical to make the carcass wall of the girdle thinner than would otherwise be the case. For example dipped latex girdle walls may be used which are as thin as .015" rather than .023 to .032" when the reinforcing fabric is not used. Corresponding reductions in the thickness of the liners may also be accomplished. Girdles made according to' the present invention are much stronger and resistant to accidental tearing. It is also practical to make the size of the porous openings or perforations in the carcass there remains a thin layer of adhesive 35 on the latex substrate. The liner sheath may, if desired, then be put under some tension to expand it some and the latex substrate inserted into it so as to contact the reinforcing stretchable fabric of the composite liner. The tension is removed from the liner sheath to allow it to contract and embrace the latex substrate which is covered with the still relatively wet adhesive layer. Gentle pressure may be applied to the composite foam liner to make it adhere uniformly to the latex substrate.

The assembly may then be flocked while the adhesive layer is still relatively wet. Flocking is done by blowing onto the surface relatively short individual fibers 23 such as cotton which adhere to the exposed wet surface areas of the carcass 26 showing through the holes 22 in the liner, as shown in FIGURE 3. The assembly is then dried and cured according to methods known in the art. After curing, the girdle and its adhered liner are stripped from the girdle form and treated to slightly harden the exposed latex surface. The girdle is then trimmed top and bottom and holes 24 which are relative- 1y small and preferably about .04 to .06 inch in diameter larger than .06" Without leaving perforation marks on the body of the wearer. Also the perforations in the carcass can be made relatively larger even if the carcass and its adhered composite liner are perforated at the same time, no marks being left on the skin of the wearer since the spongy character of the liner serves to cushion out such markings.

The foamed liner may be perforated or formed with openings therein and the reinforcing porous fabric may be separately perforated or not, the twocemented to the girdle carcass in any desired manner, and the finished girdle itself may be perforated or not. The apertures in the foamed layer and the carcass may or may not be formed through the fabric; if the supporting fabric is porous, the apertures in the foamed layer and the carcass will communicate with each other in measure because of.

that porosity. This is illustrated for example in FIG- URE 6. It is presently preferred to simultaneously perforate the foam liner and its associated fabric backing and then cement the resulting composite liner to the carcass. It is obvious however that the perforations may be produced in the foam liner, in the fabric, and in the girdle carcass in any desired manner and in any desired order; the composite liner may be perforated and then cemented to the carcass; the liner may be perforated and cemented to the carcass and then simulta neously perforated; the foam liner, the fabric component and the carcass may be separately perforated and then cemented together; or the composite linerand carcass may be cemented together and simultaneously perforated, or any other combination of perforating and combining may be used.

Preferably the composite liner may be characterized as having continuous areas and discontinuous areas or openings such as holes and flocking may be done on the surface in the exposed hole areas only, on the continuous areas only of the composite liner, or on both the continuous areas of the liner and the exposed surfaces of the hole areas, but it should be clear that the liner may be discontinuous and that the openings may be continuous as would be the case for example if circles of fabric-foam laminate of, say, 1 /2" in diameter were cemented on a substantial portion of the inside surface of the carcass /s" apart from each other. The liner thus may be described as having relatively large openings extending over a substantial portion of the surface area of the composite liner comprising continuous areas and discontinuous areas which expose part and cover part of the underlying surface of the backing layer. In the one case the continuous areas cover part of the underlying surface of the backing layer or carcass and the discontinuous areas expose part of the underlying surface without extending into the backing layer or carcass. In the other case the continuous areas expose part of the underlying surface and the discontinuous areas cover part of the underlying urface.

Stated differently, either the continuous areas or the discontinuous areas may comprise the relatively large openings and either or both may be flocked. It should be appreciated that the girdle need not be flocked at all since the advantages of increased durability and resistance to puncturing and tearing are primarily dependent upon the reinforcing composite liner. When the flock is used however, it may be present on the foam liner, on any exposed underlying surface of the fabric backing, on any exposed underlying surface of the carcass, or any combination of these; FIGURE 7 for example shows a cross section of a dipped latex girdle where flock 23 is present on the fabric 40. In general, flocking reduces the rough feel of the latex surface, increases the absorption and removal of perspiration and facilitates donning of the garment.

Instead of cementing a preformed composite foam liner to the carcass, other methods may be employed to provide a layer of composite foamed liner material adhered to the carcass. For example a sheet of extensible cotton fabric 41 is cemented to a sheet of polyurethane foam 28, by an adhesive 42 and relatively large holes 29 are simultaneously punched through both the fabric and foam. The resulting composite liner is adhesively united to backing sheet or carcass 27 by means of adhesive 25., FIGURES 4 and 5, and the thus formed laminate is cut and sewn to form a girdle. Perforations 24 and 24a may be made in the girdle as shown in FIGURE 6. Also a latex substrate may have a fabric sheet cemented to it and then be' dipped into a bath of polyurethane latex containing a blowing agent, then removing from the bath and heating to activate the blowing agent. The blowing agent gassifies the polyurethane to form an adherent foamed layer.

The invention has been illustrated by girdle structures where the carcass is made of dipped, sprayed, latex or molded, sectionally cemented or stitched rubber fabric goods but it should be understood that the practice of the invention may be applied to undergarments and other structures where the carcass is rubber, latex, graftrubber polymers, and the like.

Many changes and modifications of the invention may be made without departing from the spirit thereof and it is to be understood that all such changes and modifications are intended to be covered in the appended claims.

I claim:

1. An article for wear on the body having a perforated elastomeric outer wall and a reinforcing stretchable liner secured to its inner face and coextensive therewith, said liner comprising a stretchable fabric which has a first face secured to the said elastomeric wall and a second face secured to a stretchable foamed layer, the said liner having openings extending over a substantial portion of the surface area of the liner, comprising continuous areas and discontinuous areas which expose part and cover part of the underlying surface of the said elastomeric outer wall, the said perforations in the outer Wall extending through the said outer wall, the said stretchable fabric and the said foamed layer.

2. The article of claim 1 wherein some of the said perforations communicate with some of the said openings of the liner.

3. The article of claim 1 wherein the discontinuous areas comprise the said openings and expose part of the said underlying surface.

4. The article of claim 1 wherein the continuous areas comprise the said openings and expose part of the said underlying surface.

5. The article of claim 1 wherein the foamed layer is polyurethane.

6. The article of claim 1 wherein the liner and the exposed underlying surface of the outer wall are covered with relatively ishort individual fibers.

7. The article of claim 1 wherein the outer elastomeric-wall is dipped latex of about .015" in thickness and the foamed layer is polyurethane of about 5 to 71 in thickness.

8. A girdle having an outer wall of dipped latex and a reinforcing stretchable liner secured to its inner face and coextensive therewith, said liner comprising a stretchable fabric which has a first face secured to the said latex wall and a second face secured to a stretchable foamed layer, the said liner having predetermined dis continuous areas extending over a substantial part of the surface area of the liner, said discontinuous areas exposing the underlying surface of the said outer wall without extending into said outer wall.

9. A girdle having a deposited porous latex wall and a reinforcing stretchable liner secured to its inner face and coextensive therewith, said liner comprising a stretchable fabric which has a first face secured to the said porous latex wall and a second face secured to a layer of foamed elastomeric polyurethane, said liner having spaced holes extending over a portion of its surface and exposing underlying areas of the porous latex wall, the said porous latex wall having some of its pores communicating with the aforementioned holes in the liner.

10. The girdle of claim 8 wherein the stretchable foamed layer is polyurethane.

11. The girdle of claim 8 wherein the said liner and the said exposed underlying surface of the outer wall are covered with relatively short individual fiibers.

12. The girdle of claim 9 which has relatively short individual fibers covering portions of its inner face.

13. An undergarment with an outer wall of elastomeric material and a reinforcing stretchable liner secured to its inner face and coextensive therewith, said liner comprising a stretchable fabric which has a first face secured to the said elastomeric wall and a second face secured to a layer of stretchable foamed material, said liner being perforated and the said outer wall of elastomeric material having perforations relatively larger in size than perforations in the liner.

14. An article for wear on the body comprising an elastomeric outer wall with spaced perforations and a perforated reinforcing stretchable line secured to its inner face and coextensive therewith, said liner comprising a stretchable fabric which has a first face secured to the said elastomeric wall and a second face secured to a stretchable foamed layer, the said perforations in the outer wall, in substantial number, communicating With the perforations in the reinforcing stretchable liner.

UNITED References Cited by the Examiner STATES PATENTS Hurt 161-11 2 Callahan 16176 X Fiekers 156-252 Cadous 161--77 Alderfer 161'159 X Sudman 161159 Miller 128521 Groth 156252 Dodge 128521 FOREIGN PATENTS Great Britain.

ADELE M. EAGER, Primary Examiner 

9. A GIRDLE HAVING A DEPOSITED POROUS LATEX WALL AND A REINFORCING STRETCHABLE LINER SECURED TO ITS INNER FACE AND COAEXTENSIVE THEREWITH, SAID LINER COMPRISING A STRETCHABLE FABRIC WHICH HAS A FIRST FACE SECURED TO THE SAID POROUS LATEX WALL AND A SECOND FACE SECURED TO A LAYER OF FOAMED ELASTOMERIC POLYURETHANE, SAID LINER HAVING SPACED HOLES EXTENDING OVER A PORTION OF ITS SURFACE AND EXPOSING UNDERLYING AREAS OF THE PORTIONS LATEX WALL, THE SAID POROUS LATEX WALL HAVING SOME OF ITS PORES COMMUNICATING WITH THE AFOREMENTIONED HOLES IN THE LINER. 